APPENDIX A

Braced and Stayed Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Method of Checking Safety-Valve Capacity by Measuring Maximum Amount
of Fuel That Can Be Burned. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Fusible Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Proof Tests to Establish Maximum Allowable Working Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Suggested Rules Covering Existing Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Safety Valves for Power Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Examples of Methods of Computation of Openings in Vessel Shells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Examples of Computation of Allowable Loading on Structural Attachments to Tubes. . . . . . . . . . . . . . . . . . . . . 199
Preheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Maximum Allowable Working Pressures — Thick Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Rounded Indication Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Methods for Magnetic Particle Examination (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Methods for Liquid Penetrant Examination (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Quality Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Acceptance of Testing Laboratories and Authorized Observers for Capacity Certification of Safety and
Safety Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Figures
Fig. A-8 Detail Sketches Showing Application of PG-48 and PFT-27 to the Staying
of Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Fig. A-9 Typical Facings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Fig. A-10 Typical Forms of Fusible Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Fig. A-66 Example for Typical Nozzle Computations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Fig. A-67 Example for Typical Nozzle Computations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Fig. A-68 Example for Typical Nozzle Computations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Fig. A-69 Example for Typical Nozzle Computations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Figs. A-71–A-74 Types of Structural Attachments to Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Fig. 1 Aligned Rounded Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 2 Groups of Aligned Rounded Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 3.1 Charts for t 1⁄8 in. (3.2 mm) to 1⁄4 in. (6 mm), Inclusive . . . . . . . . . . . . . . . . . . . . . . . 205
Fig. 3.2 Charts for t Over 1⁄4 in. (6 mm) to 3⁄8 in. (10 mm), Inclusive. . . . . . . . . . . . . . . . . . . 207
Fig. 3.3 Charts for t Over 3⁄8 in. (10 mm) to 3⁄4 in. (19 mm), Inclusive. . . . . . . . . . . . . . . . . . 207
Fig. 3.4 Charts for t Over 3⁄4 in. (19 mm) to 2 in. (51 mm), Inclusive . . . . . . . . . . . . . . . . . . 208
Fig. 3.5 Charts for t Over 2 in. (51 mm) to 4 in. (102 mm), Inclusive . . . . . . . . . . . . . . . . . . 209
Fig. 3.6 Charts for t Over 4 in. (102 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Tables
A-44 Guide for Estimating Steaming Capacity Based on Heating Surface . . . . . . . . . . . . . . 186
1 Maximum Permissible Size of Rounded Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

174
 APPENDIX A
EXPLANATION OF THE CODE
CONTAINING MATTER NOT MANDATORY
UNLESS SPECIFICALLY REFERRED TO
IN THE RULES OF THE CODE

BRACED AND STAYED SURFACES by a test. The maximum number of heat units per
hour, or CH, is then determined, using the values of
A-8
H given in A-17. The weight of steam generated per
The allowable loads based on the net cross-sectional hour is found by the formula:
areas of staybolts with V-threads are computed from
the following formulas. The use of Whitworth threads Customary Units
with other pitches is permissible.
The formula for the diameter of a staybolt at the
C × H × 0.75
bottom of a V-thread is: Wp
1,100

D − (P × 1.732) p d
SI Units
where
D p diameter of staybolt over the threads, in.
C × H × 0.75
P p pitch of threads, in. Wp
2 558
p 1 /number of threads /in.
d p diameter of staybolt at bottom of threads, in.
1.732 p a constant
where
When ANSI Standard threads are used, the formula W p weight of steam generated /hr, lb (kg/hr)
becomes C p total weight or volume of fuel burned /hr (kN/
hr) at time of maximum forcing, lb (kg) or cu
D − (P × 1.732 × 0.75) p d ft/kg (m3)
H p heat of combustion of fuel, Btu /lb or Btu /cu ft
(see A-17)
The sum of the safety valve capacities marked on
METHOD OF CHECKING SAFETY- the valves shall be equal to or greater than W.
VALVE CAPACITY BY MEASURING
MAXIMUM AMOUNT OF FUEL
THAT CAN BE BURNED
A-13 Example 1
A-12
A boiler at the time of maximum forcing uses 2,150
The maximum quantity of fuel C that can be burned lb /hr of Illinois coal with a heating value of 12,100
per hour at the time of maximum forcing is determined Btu /lb. Boiler pressure is 225 psi gage.

175
Fig. A-8 2001 SECTION I

FIG. A-8 DETAIL SKETCHES SHOWING APPLICATION OF PG-48

AND PFT-27 TO THE STAYING OF BOILERS

176
 APPENDIX Fig. A-8

Area Area
r r

(1) Weld in shear (1) Weld in shear

p p
PW-19.1 PW-19.1
(2) Maximum pitch (2) Maximum pitch
15 times 15 times
stay diameter stay diameter
PFT-27.2 PFT-27.2
t (3) Max. r = 8 t
t (3) Max. r = 8 t
Min. r = 3 t Min. r = 3 t
t = Nominal t = Nominal
thickness of thickness of
tubesheet tubesheet

(i) (j)

p max. p max.

Area
p
+ 2 in.
2
(51 mm) (1) Weld in shear
PW-19.1 p p
+ 2 in. + 2 in.
(2) Maximum pitch 2 2
(51 mm) max. (51 mm) max.
15 times
stay diameter
PFT-27.3
(k) (l) Door Opening (m) Door Opening
or Mud Ring

11/2 p max.

Full penetration weld

p max. may be applied from
Wrapper or either or both sides
crown sheet of tubesheet

p max. p
+ 2 in. Tube Full penetration weld Grind
1/ in. 2 p
2 (51 mm) may be applied flush
(13 mm) min.
from either or
both sides

(n) Door Opening (o) (p)

or Mud Ring

FIG. A-8 DETAIL SKETCHES SHOWING APPLICATION OF PG-48

AND PFT-27 TO THE STAYING OF BOILERS (CONT’D)

177
Fig. A-8 2001 SECTION I

p
2 p
+ 2 in. (51 mm)
2
(PFT-27.3) p
p max.
+ 2 in. (51 mm) 2
2 PFT
(PFT-27.3) p PFT-27.9.1
p 27.9.2
2 2
p 11/ in.
16
p (17 mm)
p p Minimum
p p bearing
2
PFT-27.1 surface
p (PG-44.3)
p max. p (PFT-27.1)

Maximum pitch ”p “ may measured Maximum pitch ”p “ may be measured

circumferentially and radially only horizontally and vertically only

(1) Provide stay cross-sectional (2) Provide the number of stays (3) Diagonal stay stresses must not
area required by PG-49 based required to not exceed the exceed limits computed from
upon allowable stresses from maximum calculated pitch. PFT-32.
Table 1A of Section II, Part D.

(q)

11/ in.
16
p (17 mm)
max.
p 2 p Minimum
PFT-27.9.1 max. bearing
2 2
PFT-27.2 r r surface
11/ in. (PG-44.3)
16
p p (17 mm)
PFT-27.2 2 PFT Minimum
27.9.2 bearing
p p surface
p 2
p
p
p p
p
2
PFT-27.1
p
p max. p (PFT-27.1)

Maximum pitch ”p “ may be measured Maximum pitch ”p “ may be measured

circumferentially and radially only horizontally and vertically only

(1) Provide stay cross-sectional (2) Provide the number of stays (3) Diagonal stay stresses must not
area required by PG-49 based required to not exceed the exceed limits computed from
upon allowable stresses from maximum calculated pitch. PFT-32.
Table 1A of Section II, Part D.

(r)

FIG. A-8 DETAIL SKETCHES SHOWING APPLICATION OF PG-48

AND PFT-27 TO THE STAYING OF BOILERS (CONT’D)

178
A-13 APPENDIX A-17

A-15 Example 3
An oil-fired boiler at maximum forcing uses 1,000
lb /hr of crude oil (Texas). Boiler pressure is 275
psi gage.

C × H p 1,000 × 18,500 p 18,500,000

C × H × 0.75
Wp p 12,620
1,100

A-16 Example 4
A boiler fired with natural gas consumes 3,000 cu
ft /hr. The working pressure is 150 psi gage.

C × H p 3,000 × 960 p 2,880,000

C × H × 0.75
Wp p 1,960
1,100

A-17
FIG. A-9 TYPICAL FACINGS
For the purpose of checking the safety valve capacity
as described in A-12, the following values of heats of
combustion of various fuels may be used:
C × H p 2,150 × 12,100 p 26,015,000
H p Btu /lb (kJ/kg)
C × H × 0.75 Semibituminous coal . . . . . . . . . . . . . . . . . . . . . . . 14,500 34 000
Wp p 17,740 Anthracite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,700 32 000
1,100
Screenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,500 29 000
Coke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,500 31 000
Wood, hard or soft, kiln dried. . . . . . . . . . . . . . . 7,700 18 000
Wood, hard or soft, air dried. . . . . . . . . . . . . . . . 6,200 14 000
A-14 Example 2 Wood shavings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,400 14 400
Peat, air dried, 25% moisture . . . . . . . . . . . . . . . 7,500 17 000
Wood shavings of heat of combustion of 6,400 Btu /
Lignite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 23 300
lb are burned under a boiler at the maximum rate of Kerosene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,000 46 500
2,000 lb /hr. Boiler pressure is 100 psi gage. Petroleum, crude oil, Pennsylvania . . . . . . . . . . . 20,700 48 000
Petroleum, crude oil, Texas . . . . . . . . . . . . . . . . . 18,500 43 000

C × H p 2,000 × 6,400 p 12,800,000 H p Btu /cu ft (kJ/m3)

Natural gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 960 35 700
Blast-furnace gas . . . . . . . . . . . . . . . . . . . . . . . . . . 100 3 700
C × H × 0.75 Producer gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 5 600
Wp p 8,730
1,100 Water gas, uncarbureted . . . . . . . . . . . . . . . . . . . . 290 11 000

179
A-18 2001 SECTION I A-18.5

1/ in. (13 mm)

2

3/ in.
4
(19 mm)
1 in. (25 mm)

3/ in. 1/
8 2 in. (13 mm)
(10 mm)
1/ in. (13 mm)
2 Installation
Plug type

(a) Water side plugs

1/ in. (13 mm)

2

3/ in. (19 mm)

4
1 in. (25 mm)

3/ 1 in.
8 in.
1/ in. (13 mm) (25 mm)
(10 mm) 2
max.
1/ in. (13 mm)
2 Installation
Plug type

1/ in. (13 mm)

2

3/ in. (19 mm)

1 in. (10 mm) 4

3/ in. 1/ in. (13 mm)

8 2
(10 mm)
Plug type Installation

(b) Fire side plugs

GENERAL NOTE: All dimensions minimum unless otherwise specified

FIG. A-10 TYPICAL FORMS OF FUSIBLE PLUGS

AUTOMATIC WATER GAGES of contact with the seat must not be greater than two-
thirds of the diameter of the check ball. The space
A-18 around each ball must be not less than 1⁄8 in. (3.2 mm),
Automatic shutoff valves on water gages, if permitted and the travel movement from the normal resting place
to be used, shall conform to the following requirements. to the seat must be not less than 1⁄4 in. (6 mm).
A-18.1 Check valves in upper and lower fittings A-18.4 The ball seat in the upper fitting must be a
shall be of solid noncorrosive metal ball type to avoid flat seat with either a square or hexagonal opening, or
need for guides. otherwise arranged so that the steam passage can never
A-18.2 Ball check valves in upper and lower fittings be completely closed by this valve.
must open by gravity and the lower ball check valve
A-18.5 The shutoff valve in the upper fitting must
must rise vertically to its seat.
have a projection that holds the ball at least 1⁄4 in.
A-18.3 The check balls must not be smaller than 1⁄2 (6 mm) away from its seat when the shutoff valve is
in. (13 mm) in diameter, and the diameter of the circle closed.

180
A-18.6 APPENDIX A-21

A-18.6 The balls must be accessible for inspection. A-20.3 Typical designs of fusible plugs are given
Means must be provided for removal and inspection in Fig. A-10.
of the lower ball check valve while the boiler is under
steam pressure. A-20.4 The bore of the casing shall be tapered
These restrictions do not apply to closing the valves continuously from the water end of the casing for a
by external methods. distance of at least 1 in. to a diameter of not less than
3
⁄8 in. (10 mm) at a point not less than 1⁄2 in. (13 mm)
from the fire end. The diameter of the bore at either
FUSIBLE PLUGS end shall be not less than 1⁄2 in. (13 mm). The hole
on the fire end shall be as large as possible and may
A-19 be of any shape provided the cross-sectional area at
A-19.1 Fire-actuated fusible plugs, if used, except all points is greater than the area of the least cross
as provided in A-20.9, shall be filled with tin of the section of the fusible metal.
following composition, having a melting point between
445°F and 450°F (229°C and 232°C): A-20.5 A fusible plug shall be of such length that
when installed it shall project at least 3⁄4 in. (19 mm)
Pure tin, min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.3% on the water side of the plate, tube, or flue. It shall
Copper, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00.5% extend through the plate, tube, or flue on the fire side
Lead, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00.1% as little as possible but not more than 1 in. (25 mm).
Total impurities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00.7%

A-20.6 A fire side plug may be designed so as to

A-19.2 The fusible metal shall extend from the water be inserted by means of a plug type wrench, so as to
end of the plug to the point of least diameter of the reduce the projection on the fire side.
hole and shall be carefully alloyed to the casing. A
test shall be made to determine that the fusible metal A-20.7 If a fire-actuated fusible plug is inserted in
is not loose in the plug. a tube, the tube wall at the plug shall be not less than
A-19.3 Fusible plugs shall be renewed at least once 0.22 in. thick, or sufficient to give four full threads.
each year. Casings that have been used shall not be
refilled. A-20.8 Fusible plugs that comply with the require-
ments of A-19 and A-20 must be stamped on the
A-19.4 Fusible plugs filled with tin as specified in casing with the name of the manufacturer, and on the
A-19.1 shall not be used for pressures and temperatures water end of the fusible metal “ASME Std.”
that will cause the plug to fail while it is submerged
in the boiler water.
A-20.9 Fusible metal, other than tin as specified in
The fusible metal may be partly replaced by a bronze
A-19.1, for use under temperatures exceeding 450°F,
plug loosely fitted to the hole and of such size that it
may be used and the casing may be made of other
will pass freely through the hole on the fire side, from
material and shape than specified in A-20.2 through
which side it must be inserted into the casing. Such
A-20.4 if the metal and the casing are approved by
plug shall be properly alloyed to the casing with the
the administrative authority. Such plugs shall not be
same fusible metal as required by A-19.1.
marked as “ASME Std.”

A-20
A-20.1 Water side plugs are fusible plugs that are
inserted from the water side of the plate, flue, or tube A-21
to which they are attached. Fire side plugs are fusible
Fire-actuated fusible plugs, if used, shall be located
plugs inserted from the fire side of the plate, flue, or
at the lowest permissible water level as determined by
tube to which they are attached.
the boiler Manufacturer; steam-actuated plugs, if used,
A-20.2 The casing of the fusible plugs shall be shall be so located that they will operate when the
made of a composition conforming to SB-61 or from water level is at the point where a fire-actuated fusible
phosphor-bronze rods conforming to ASTM B 139. plug would be located.

181
A-22 2001 SECTION I A-22.5

PROOF TESTS TO ESTABLISH pressure in the pressure part shall be increased gradually
MAXIMUM ALLOWABLE WORKING until approximately one-half the anticipated maximum
PRESSURE allowable working pressure is reached. Thereafter, the
test pressure shall be increased in steps of approximately
A-22 one-tenth or less of the anticipated maximum allowable
A-22.1 Scope. The maximum allowable working working pressure until the pressure required by the test
pressure for pressure parts of boilers for which the procedure is reached. The pressure shall be held station-
strength cannot be computed with a satisfactory assur- ary at the end of each increment for a sufficient time
ance of accuracy shall be established in accordance to allow the observations required by the test procedure
with the requirements of this paragraph, using one of to be made, and shall be released to zero to permit
the test procedures applicable to the type of loading determination of any permanent strain or displacement
and to the material used in its construction. after any pressure increment that indicates an increase in
The tests in these paragraphs may be used only for strain or displacement over the previous equal pressure
the purpose of establishing the maximum allowable increment.
working pressure of those elements or component parts
A-22.4 Critical Areas. As a check that the measure-
for which the thickness cannot be determined by means
ments are being taken on the most critical areas, the
of the design rules given in this Code. The maximum
Inspector may require a brittle coating to be applied
allowable working pressure of all other elements or
on all areas of probable high stress concentrations in
component parts shall not be greater than that deter-
the test procedures given in A-22.6.1 and A-22.6.2.
mined by means of the applicable design rules.
The surfaces shall be suitably clean before the coating
A-22.2 Tests is applied in order to obtain satisfactory adhesion. The
technique shall be suited to the coating material.
A-22.2.1 Types. Provision is made for two types
of tests for determining the internal maximum allowable NOTE: Strains should be measured as they apply to membrane
working pressure: stresses and to bending stresses within the following range. It is
recognized that high localized and secondary bending stresses may
A-[Link] Tests based on yielding of the part exist in pressure parts designed and fabricated in accordance with
these rules. Insofar as practical, design rules for details have been
to be tested. These tests are limited to materials with written to hold such stresses at a safe level consistent with experience.
a ratio of minimum specified yield to minimum specified
ultimate strength of 0.625 or less. A-22.5 Yield Strength and Tensile Strength. For
proof tests based on yielding, A-22.6.1 or A-22.6.2,
A-[Link] Tests based on bursting of the part. the yield strength (or yield point for those materials
which exhibit that type of yield behavior indicated by
A-22.2.2 Retests. A retest shall be allowed on a
a “sharp-kneed” portion of the stress–strain diagram)
duplicate pressure part if errors or irregularities are
of the material in the part tested, shall be determined in
obvious in the test results.
accordance with the method prescribed in the applicable
A-22.2.3 Precautions. Safety of testing personnel material specification and as described in ASTM E 8,
should be given serious consideration when conducting Tension Testing of Metallic Materials. For proof tests
proof tests, and particular care should be taken during based on bursting, A-22.6.3, the tensile strength instead
bursting tests in A-22.6.3. of the yield strength of the material in the part tested
shall be similarly determined.
A-22.3 Pressure Yield or tensile strength so determined shall be the
A-22.3.1 Previously Applied. The pressure parts average from three or four specimens cut from the part
for which the maximum allowable working pressure is tested after the test is completed. The specimens shall
to be established shall not previously have been be cut from a location where the stress during the test
subjected to a pressure greater than 11⁄2 times the has not exceeded the yield strength. The specimens
desired or anticipated maximum allowable working shall not be oxygen cut because this might affect the
pressure, adjusted for design temperature as provided strength of the material.
in A-22.8. When excess stock from the same piece of wrought
material is available and has been given the same
A-22.3.2 Application. In the procedures given in postweld heat treatment as the pressure part, the test
A-22.6.1 for the Strain Measurement Test, and A-22.6.2 specimens may be cut from this excess stock. The
for the Displacement Measurement Test, the hydrostatic specimens shall not be removed by flame cutting or

182
A-22.5 APPENDIX A-[Link]

any other method involving sufficient heat to affect A-[Link].1 If the average yield strength is
the properties of the specimen. determined by A-22.5:
If yield or tensile strength are not determined by
test specimens from the pressure part tested, alternative Ys
P p 0.5H
methods are given in A-22.6.1, A-22.6.2, and A-22.6.3 Ya
for evaluation of proof test results to establish the
maximum allowable working pressure.
A-[Link].2 If the actual average yield strength
A-22.6 Procedure is not determined by test specimens:

A-22.6.1 Strain Measurement Test P p 0.4H

A-[Link] Subject to limitations of A-[Link],
this procedure may be used for pressure parts under where
internal pressure, constructed of any material permitted H p hydrostatic test pressure, psi (kPa), at which the
to be used under the rules of Section I. Strains shall test was stopped in accordance with A-[Link]
be measured in the direction of the maximum stress Ys p yield strength — specified minimum
at the most highly stressed parts (see A-22.4) by means Ya p yield strength — actual average from test spec-
of strain gages of any type capable of indicating strains imens
to 0.00005 in. /in. Pressure shall be applied as provided The maximum allowable working pressure at other
in A-22.3.2. temperatures shall be determined as provided in A-22.8.

A-[Link] After each increment of pressure has A-22.6.2 Displacement Measurement Test
been applied, readings of the strain gages and the A-[Link] Subject to the limitations of A-
hydrostatic pressure shall be taken and recorded. The [Link] this procedure may be used only for pressure
pressure shall be released and any permanent strain at parts under internal pressure, constructed of materials
each gage shall be determined after any pressure incre- having a definitely determinable yield point. Displace-
ment that indicates an increase in strain for this incre- ment shall be measured at the most highly stressed
ment over the previous equal pressure increment. Only parts (see A-22.4) by means of measuring devices of
one application of each increment of pressure is required. any type capable of measuring to 0.001 in. (0.02 mm).
This displacement may be measured between two dia-
A-[Link] Two curves of strain against test metrically opposed reference points in a symmetrical
pressure shall be plotted for each gage line as the test structure, or between a reference point and a fixed
progresses, one showing the strain under pressure and base point. Pressure shall be applied as provided in
one showing the permanent strain when the pressure A-22.3.2.
is removed. The test may be discontinued when the
test pressure reaches the value H which will, by the A-[Link] After each increment of pressure has
formula, justify the desired working pressure, but shall been applied, readings of the displacement and the
not exceed the pressure at which the plotted points for hydrostatic pressure shall be taken and recorded. The
the most highly strained gage line reaches the value pressure shall be released and any permanent displace-
given below for the material used. ment shall be determined after any pressure increment
that indicates an increase in measured displacement for
A-[Link].1 0.2% permanent strain for carbon, this increment over the previous equal pressure incre-
low-alloy and high-alloy steels. ment. Only one application of each increment is re-
quired. Care must be taken to assure that the readings
A-[Link].2 0.5% strain under pressure for cop- represent only displacements of the parts on which
per-base alloys. measurements are being made and do not include any
slip of the measuring devices or any movement of the
A-[Link].3 0.2% permanent strain for nickel fixed base points or of the pressure part as a whole.
alloys.
A-[Link] Two curves of displacement against
A-[Link] The maximum allowable working test pressure shall be plotted for each reference point
pressure P in pounds per square inch at test temperature as the test progresses, one showing the displacement
for parts tested under this paragraph shall be computed under pressure, and one showing the permanent displace-
by one of the following formulas. ment when the pressure is removed. The application

183
A-[Link] 2001 SECTION I A-[Link].3

of pressure shall be stopped when it is evident that where

the curve through the points representing displacement H p hydrostatic test pressure coincident with the
under pressure has deviated from a straight line. proportional limit of the weakest element of the
component part tested, psi (kPa)
A-[Link] The pressure coincident with the Ys p yield strength — specified minimum
proportional limit of the material shall be determined Ya p yield strength — actual average from test spec-
by noting the pressure at which the curve representing imens
displacement under pressure deviates from a straight S p specified minimum tensile strength
line. The pressure at the proportional limit may be When the formula in A-[Link].2.1 or A-[Link].2.2
checked from the curve of permanent displacement by is used, the material in the pressure part shall have
locating the point where the permanent displacement had no appreciable cold working or other treatment
begins to increase regularly with further increases in that would tend to raise the yield strength above the
pressure. Permanent deformation at the beginning of normal.
the curve that results from the equalization of stresses The maximum allowable working pressure at other
and irregularities in the material may be disregarded. temperatures shall be determined as provided in A-22.8.
The maximum allowable working pressure P in
pounds per square inch at test temperature for parts A-22.6.3 Bursting Tests
tested under this paragraph shall be computed by one
A-[Link] This procedure may be used for
of the following formulas.
pressure parts under internal pressure when constructed
A-[Link].1 If the average yield strength is of any material permitted to be used under the rules
determined by A-22.5: of Section I. The maximum allowable working pressure
of any component part proof tested by this method
shall be established by a hydrostatic test to failure by
Ys
P p 0.5H rupture of a full-size sample of such pressure part. The
Ya
hydrostatic pressure at which rupture occurs must be
determined. Alternatively, the test may be stopped
at any pressure before rupture that will satisfy the
A-[Link].2 In order to eliminate the necessity
requirements for the desired maximum allowable work-
of cutting tensile specimens and determining the actual
ing pressure. The item so tested shall not be used for
yield strength of the material under test, one of the
Code construction.
following formulas may be used to determine the
maximum allowable working pressure:
A-[Link] The maximum allowable working
A-[Link].2.1 For carbon steel, meeting an ac- pressure P in pounds per square inch at test temperature
ceptable Code specification, with a specified minimum for parts tested under this paragraph shall be computed
tensile strength of not over 70,000 psi (480 MPa): by one of the following formulas.

Customary Units A-[Link].1 Parts constructed of materials other 01

than cast materials:

冢S + 5,000冣
S
P p 0.5H
B S
Pp ×
4 (Sa or Sm )
SI Units

冢S + 34 000冣
S
P p 0.5H
A-[Link].2 Parts constructed of cast iron:

B S
A-[Link].2.2 For any material listed in Tables Pp ×
6.67 Sb
1A and 1B of Section II, Part D, as acceptable for
Section I construction:

P p 0.4H A-[Link].3 Parts constructed of nodular iron:

184
 A-[Link].3 APPENDIX A-28

Bf S A-22.9 Duplicate Parts. When the maximum allow-

Pp ×
5 Sb able working pressure of a pressure part has been
established by a proof test, duplicate parts of the same
materials, design and construction need not be proof
01 A-[Link].4 For parts constructed of cast materi- tested but shall be given the standard hydrostatic test
als, except cast iron and nodular iron: at 11⁄2 times the maximum allowable working pressure.
The dimensions and minimum thickness of the structure
to be tested should not vary materially from those
Bf S actually used. A geometrically similar part may be
Pp ×
4 (Sa or Sm ) qualified by a series of tests covering the complete
size range of the pressure part.
where
B p bursting test pressure, psi (kPa) A-22.10 Inspection. Tests to establish the maximum
f p casting quality factor as defined in PG-25 allowable working pressure for pressure parts shall be
S p specified minimum tensile strength (MPa) witnessed and approved by an Authorized Inspector.
Sa p average actual tensile strength of test specimens A-22.11 Test Gages
Sm p maximum tensile strength of range of specifica- A-22.11.1 An indicating gage shall be connected
tion (MPa) directly to the pressure parts. If the indicating gage is not
Sb p minimum tensile strength of test bar (MPa) readily visible to the operator controlling the pressure
For all materials except cast iron and nodular iron, the applied, an additional indicating gage shall be provided
maximum allowable working pressure at other tempera- where it will be visible to the operator throughout the
tures shall be determined as provided in A-22.8. duration of the test. For large pressure parts, it is
recommended that a recording gage be used in addition
A-22.7 Parts Subject to Collapse to indicating gages.
A-22.7.1 Parts of the boiler normally subject to A-22.11.2 Pressure gages used in testing shall
collapse for which specified rules are not provided in this comply with PG-99.4.
Section shall withstand without excessive deformation a
hydrostatic test of not less than three times the desired A-22.11.3 All gages used in proof testing shall
maximum allowable working pressure. be calibrated against a standard deadweight tester or
a calibrated master gage before the proof test is begun.
A-22.7.2 The maximum allowable working pres- Gages shall be recalibrated at any time that there is
sure at other than test temperatures shall be determined reason to believe they are in error.
as provided in A-22.8.

A-22.8 Higher Temperatures. The maximum allow- A-24 Table PG-23.1

able working pressure for pressure parts that are de- See Table 1A of Section II, Part D.
signed for temperatures at which the allowable stress
value of the material is less than that at the test
temperature shall be determined by the following A-25 Table PG-23.2
formula: See Table 1B of Section II, Part D.
S
Po p Pt o
St
A-26 Table PG-23.3
where
Po p maximum allowable working pressure at design See Table 1B of Section II, Part D.
temperature, psi (kPa)
Pt p maximum allowable working pressure at test
A-27 Table PG-23.4
temperature, psi (kPa)
So p maximum allowable stress value at the design See Table Y-1 of Section II, Part D.
temperature, as given in Table 1A or 1B of
Section II, Part D, psi (kPa)
A-28 Figures PFT-51.1.1–PFT-51.1.7
St p maximum allowable stress value at test tempera-
ture as given in Table 1A or 1B of Section II, See Subpart 3, External Pressure Charts in Section
Part D, psi (kPa) II, Part D.

185
A-30 2001 SECTION I A-48

TABLE A-44 upon the maximum amount of steam that can flow
GUIDE FOR ESTIMATING STEAMING into the lower pressure system. The additional safety
CAPACITY BASED ON HEATING SURFACE valves shall have at least one valve set at a pressure
Firetube Watertube not to exceed the lowest allowable pressure and the
Boilers Boilers other valves shall be set within a range not to exceed
Boiler heating surface 3% above that pressure.
Hand fired 5 6
Stoker fired 7 8
Oil, gas, or pulverized fuel fired 8 10
Waterwall heating surface A-46
Hand fired 8 8
If the safety valve or safety relief valve capacity
Stoker fired 10 12
Oil, gas, or pulverized fuel fired 14 16 cannot be determined or if it is desirable to verify the
computations, the capacity may be checked in one of
GENERAL NOTE: When a boiler is fired only by a gas having a heat
value not in excess of 200 Btu/cu ft, the minimum safety valve or the three following ways, and if found insufficient,
safety relief valve relieving capacity may be based on the values given additional capacity shall be provided.
for hand-fired boilers above.
A-46.1 By making an accumulation test, that is, by
shutting off all other steam-discharge outlets from the
boiler and forcing the fires to the maximum. The safety
valve equipment shall be sufficient to prevent an excess
SUGGESTED RULES COVERING pressure beyond that specified in PG-67.2. This method
EXISTING INSTALLATIONS should not be used on a boiler with a superheater or
reheater or on a high-temperature water boiler.
A-30
A-46.2 By measuring the maximum amount of fuel
For existing riveted construction, use suggested rules that can be burned and computing the corresponding
in the 1971 Edition of Section I. evaporative capacity upon the basis of the heating value
of the fuel (see A-12 through A-17).

SAFETY VALVES FOR POWER BOILERS A-46.3 By determining the maximum evaporative
capacity by measuring the feedwater. The sum of the
A-44 safety valve capacities marked on the valves shall be
The minimum safety valve or safety relief valve equal to or greater than the maximum evaporative
relieving capacity for other than electric boilers, waste capacity of the boiler. This method shall not be used
heat boilers, organic fluid vaporizers, and forced-flow on high-temperature water boilers.
steam generators with no fixed steam and waterline,
when provided in accordance with PG-67.4.3, may be
estimated on the basis of the pounds of steam generated A-48
per hour per square foot of boiler heating surface and
When operating conditions are changed, or additional
waterwall heating surface, as given in Table A-44.
heating surface such as water screens or waterwalls is
In many cases, a greater relieving capacity of safety
connected to the boiler circulation, the safety valve or
relief valves will have to be provided than that estimated
safety relief valve capacity shall be increased, if neces-
using Table A-44, in order to meet the requirements
sary, to meet the new conditions and be in accordance
of the first paragraph of PG-67.2.
with PG-67.2. The additional valves required on account
of changed conditions may be installed on the piping
between the boiler and the main stop valve except
A-45
when the boiler is equipped with a superheater or other
When boilers of different maximum allowable work- piece of apparatus. In the latter case they may be
ing pressures with minimum safety valve settings vary- installed on the piping between the boiler drum and
ing more than 6% are so connected that steam can the inlet to the superheater or other apparatus, provided
flow toward the lower pressure units, the latter shall that the piping between the boiler and safety valve (or
be protected by additional safety valve capacity, if valves) connection has a cross-sectional area of at least
necessary, on the lower pressure side of the system. three times the combined areas of the inlet connections
The additional safety valve capacity shall be based to the safety valves applied to it.

186
A-63.2 APPENDIX A-66

A-63.2 During a hydrostatic test of a boiler, the exception provided in PG-[Link] permitting the open-
safety valve or valves shall be removed or each valve ing without requiring a calculation to determine the
disk shall be held to its seat by means of a testing availability of compensation in the shell. PG-39.5.1
clamp and not by screwing down the compression and Table PG-39, however, require a minimum plate
screw upon the spring. thickness and thread engagement greater than that pro-
vided by the shell thickness. Therefore, the connection
cannot be made as originally stated; however, either a
A-64 Repairs to Existing Boilers heavier shell plate or a built-up pad or properly attached
plate or fitting could be used to provide the minimum
Where repairs are necessary that in any way affect metal thickness and number of threads as required by
the working pressure or safety of a boiler, a state
PG-39 and Table PG-39. Should a plate or fitting,
inspector, municipal inspector, or an inspector employed attached by welding, be used, the rules in PG-37, PW-
regularly by an insurance company, which is authorized 15, and PW-16 shall be met.
to do a boiler insurance business in the state in which
the boiler is used, shall be called for consultation and
advice as to the best method of making such repairs;
after such repairs are made they shall be subject to A-66 A02
the approval of a state inspector, municipal inspector,
or an inspector regularly employed by an insurance A forged steel fitting as shown in Fig. A-66, with
company that is authorized to do a boiler insurance a female 3 in. nominal pipe thread over the full fitting
business in the state in which the boiler is used. depth is to be inserted and welded into a vessel shell.
The maximum allowable stress is 15,000 psi for the
fitting material and 17,500 psi for the vessel shell
material. The maximum allowable working pressure of
EXAMPLES OF METHODS OF the vessel is 375 psig. See Fig. A-66 for nozzle and
COMPUTATION OF OPENINGS IN vessel dimensions.
VESSEL SHELLS The fitting complies with the size, pressure, and
Application of the rules in PG-32, PG-33, PG-36 thread depth limitations provided in PG-39.5 and Table
through PG-39, PW-15, and PW-16 are given in the PG-39. The welded attachment does not qualify for
following examples. Common assumptions in all the the exception that exempts the design from calculation
examples are that the design temperature corresponds of the required reinforcement as provided in PG-32
to the temperature of saturated steam at the maximum and must, therefore, comply with PG-33 as follows.
allowable working pressure, that all areas are expressed Minimum required thickness for reinforcement consider-
in terms of equivalent area of the vessel material (see ation:
PG-37), that the corrosion /erosion allowance is zero,
48
and that all openings are single openings unless other- Rv, the inside radius of the vessel p
2
wise noted. Subscripts have been provided where neces-
sary to eliminate confusion where an algebraic value p 24 in.
has more than one meaning as used in these examples.
(Sn denotes allowable stress of the nozzle material, Sv PRv
Shell tr p
denotes allowable stress of the vessel material, Rn Sv − (1 − y)P
denotes radius of nozzle, etc.) The values t and tn are
assumed to be minimum in these examples. 375 ⴛ 24
p
17,500 − (1 − 0.4) ⴛ 375

p 0.521 in.
A-65
A boiler shell, designed for 595 psig maximum PRn
Nozzle trn p
allowable working pressure, has an inside diameter of Sn − (1 − y)P
36 in. and is made of 1⁄2 in. thick plate. Is it permissible
to install an NPS 2 connection by tapping a hole for 375 ⴛ 1.75
p
the pipe directly into the shell? 15,000 − (1 − 0.4) ⴛ 375
The NPS 2 connection complies with the pressure-
size limitations in PG-39.5.2 and qualifies for the p 0.044 in.

187
 A-66 2001 SECTION I A-66

41/4 in. dia WL1 = 3/8 in.

3/ in. 31/2 in.
8

5/ in.
Limits of
8 5/ in. reinforcements
8

2 in.
3/ in.

48 in. inside diameter

4

3 in. NPT

vessel
51/4 in. O.D. Lip WL3 = 3/8 in.

GENERAL NOTE: This example was performed using computer software. The example was generated by performing the entire calculation
without rounding off during each step. Accuracy of the final results beyond three significant figures is not intended or required.

A02 FIG. A-66 EXAMPLE FOR TYPICAL NOZZLE COMPUTATIONS

Area of reinforcement required (see PG-33.3 and Fig. Area of reinforcement available in the nozzle and nozzle
PG-33.1): lip internal of the vessel (see PG-33.3, PG-36.4.2, and
Fig. PG-33.1). (Due to the nozzle lip, modification of
A p (d + 2tn) tr F the equation provided in Fig. PG-33.1 will be required
to reflect the actual area present.):
p (3.5 + 2 ⴛ 0.375) ⴛ 0.521 ⴛ 1.0
A3 p 2tn tr1 h + area present in lip
p 2.214 sq in.
p 2 ⴛ 0.375 (15,000/17,500)(1.375)
+ 2 ⴛ 0.5 ⴛ 0.75
Area of reinforcement available in vessel wall (see p 1.634 sq in.
PG-33.3, PG-36.4.1, and Fig. PG-33.1):

Area of reinforcement available in attachment welds

A1p (d − 2tn)(t − Ftr )
(see PG-36.4.3 and Fig. PG-33.1):
p (3.5 − 2 ⴛ 0.375)(0.625 − 1.0 ⴛ 0.521)
p 0.286 sq in. A4p (WL12 + WL22) (Sn / Sv)

p (0.3752 + 0.3752) (15,000 / 17,500)

Area of reinforcement available in the nozzle wall p 0.241 sq in.
external of the vessel (see PG-33.3, PG-36.4.2, and Total area of reinforcement available:
Fig. PG-33.1):
In that the actual nozzle projection is less than that
permitted within the limits of reinforcement, modifica- A1 + A2 + A3 + A41 + A43 p 2.515 sq in. ≥ A
tion of the equation provided in PG-33.1 will be required
to reflect the actual area available for reinforcement.
as required for demonstration of compliance with PG-33.

A2 p 2 (tn − trn )(actual projection) (Sn / Sv ) Compliance with PG-37 and PW-15 is demonstrated
by the following calculations.
p 2 ⴛ (0.375 − 0.044) ⴛ 0.625 ⴛ (15,000 / 17,500)
Required minimum strength to be provided by the
p 0.354 sq in. welds (see PG-37 and PW-15):

188
A-66 APPENDIX A-67

W p (A − A1) Sv Verification:
p (2.214 − 0.286) 17,500
p 33,742 lb (t1 + t2 p 0.530) ≥ (1.25 tmin p 0.469)

(t1 p 0.265) ≥ 0.25

Strength of the welds (see PG-37 and PW-15): (t2 p 0.265) ≥ 0.25

Internal fillet weld in shear As verified by the above demonstrations, the design is
proved to be in compliance with the requirements of
Section I.
p 1⁄2 ␲ WL3 (OD lip + WL3) (factor in PW-15.2) Sn
A-67 A02
p 1⁄2 ⴛ 3.142 ⴛ 0.375 ⴛ (5.25 + 0.375) ⴛ 0.49 ⴛ 15,000
A vessel shell has a studding outlet connection
p 24,353 lb mounted as shown in Fig. A-67. The maximum allow-
able stress of both the vessel and studding outlet
External fillet weld in shear material is 12,500 psi. The maximum allowable working
pressure of the design is 325 psig. See Fig. A-67 for
vessel and studding outlet dimensions.
p 1⁄2 ␲ WL1 (dl + WL1 ) (factor in PW-15.2) Sn The studding outlet conforms to the requirements of
PG-39.4, both in arrangement and in tapped stud hole
p 0.5 ⴛ 3.142 ⴛ 0.375 ⴛ (4.25 + 0.375) requirements. The welded attachment does not qualify
ⴛ 0.49 ⴛ 15,000 for the exception provided in PG-32 and must therefore
p 20,027 lb comply with PG-33 as follows.

The combined strength of the welds equals 44,384 lb Minimum required thickness for reinforcement consider-
≥ W as required for compliance with PG-37 and PW-15. ation:
Verification of the minimum weld sizing as required
by PW-16.1 and Fig. PW-16.1, sketch (u-2), is demon- PRv
Shell tr p
strated by the following. Sv − (1 − y) P
Required per Fig. PW-16.1, sketch (u-2):
325 ⴛ 30
p
12,500 − (1 − 0.4) ⴛ 325
t1 + t2 ≥ 1.25 tmin
p 0.792 in.
t1 ≥ 0.25
Nozzle trn p 0.0 [see Fig. PG-36.4, sketch (a)]
t2 ≥ 0.25
Area of reinforcement required (see PG-33.2):

Actual per Fig. A-66: A p tr Fd

p 0.79236 ⴛ 1.0 ⴛ 7.5
t1 p WL1 sin 45°
p 5.943 sq in.
p 0.375 ⴛ 0.7071

p 0.265 in. Area of reinforcement available in the vessel wall (see

PG-36.4.1):
t2 p WL2 sin 45°

p 0.375 ⴛ 0.7071 A1 p (t − Ftr) d

p 0.265 in. p (1.0 − 1.0 ⴛ 0.79236) ⴛ 7.5
tmin p 0.375 (based on tn) p 1.557 sq in.

189
 A-67 2001 SECTION I A-67

7/ in.
9 Thd./in. Class 2B fit
8
by 15/16 in. tapped depth

15 in. limit of reinforcement

121/2 in.

6 in.
WL1 =
17/ in.
32 11/2 in. (te )

1 in.

inside diameter
WL3 = 3/4 in.
71/2 in.

vessel
60 in.
GENERAL NOTES:
(a) Stud holes are staggered about the line of the longitudinal section and are shown for clarification only.
(b) This example was performed using computer software. The example was generated by performing the entire calculation without rounding
off during each step. Accuracy of the final results beyond three significant figures is not intended or required.

A02 FIG. A-67 EXAMPLE FOR TYPICAL NOZZLE COMPUTATIONS

Area of reinforcement available in attachment welds Required minimum strength to be provided by the
(see PG-36.4.3): welds (see PG-37 and PW-15):

A4 p WL12 + WL3 W p (A − A1) Sv

p (5.943 − 1.557) ⴛ 12,500
p 0.5312 + 0.752
p 54,818 lb
p 0.845 sq in.

Strength of the welds (see PG-37 and PW-15):

Area of reinforcement available in pad (see PG-36.4.3): External fillet weld in shear

A5 p ([Link] − [Link]) te p 1⁄2 ␲ WL1 ([Link] + WL1) (factor in PW-15.2) S

p (12.5 − 6) ⴛ 1.5 p 0.5 ⴛ 3.14159 ⴛ 0.53125 ⴛ (12.5 + 0.53125)

ⴛ 0.49 ⴛ 12,500
p 9.75 sq in.
p 66,606 lb

Total area of reinforcement available:

Internal fillet weld in shear

A1 + A4 + A5 p 12.152 sq in. ≥ A
p 1⁄2 ␲ WL3 (dl − WL3) (factor in PW-15.2) S

p 0.5 ⴛ 3.142 ⴛ 0.75 ⴛ (7.5 − 0.75)

as required for demonstration of compliance with PG-33.
ⴛ 0.49 ⴛ 12,500
Compliance with PG-37 and PW-15 is demonstrated
by the following calculations. p 48,707 lb

190
A-67 APPENDIX A-69

The combined strength of the welds equals 115,313 lb Check to determine if the welded attachment qualifies
≥ W as required for compliance with PG-37 and PW-15. for the exception provided in PG-32.
Verification of the minimum weld sizing as required
PD
by PW-16.1 and Fig. PW-16.1, sketch (t) is demon- Kp [see PG-32.1.2, Eq. (2)]
1.82 St
strated by the following.
250 ⴛ 30.875
p
1.82 ⴛ 13,700 ⴛ 0.4375
Required per Fig. PW-16.1(t):
External fillet weld throat ≥ 1⁄2t min p 0.7076 or 70.76%
Internal fillet weld throat ≥ 0.7t min
Dt p 30.875 ⴛ 0.4375
Actual per Fig. A-67:
External fillet weld throat p 13.5078

p WL1 sin 45° From Fig. PG-32, maximum size of opening with
p 0.531 ⴛ 0.707 inherent compensation is 4.35 in.
p 0.376 in.
Nominal ID of NPS 4 extra strong pipe is:
Internal fillet weld throat
4.5 − 2(0.337) p 3.826 in.

p WL3 sin 45° Since ID is less than maximum size opening from Fig.
p 0.75 ⴛ 0.707 PG-32, no calculation need be made to demonstrate
p 0.530 in. compliance with the compensation requirements of PG-
tmin p 0.75 (based on PW-16.2) 33 (see PG-[Link]).

Verification:
A-69 A02

(External fillet weld throat p 0.376) A vessel has a series of welded connections in a
definite pattern as shown in Fig. A-69. The maximum
≥ (1⁄2 t min p 0.375) allowable stress of all nozzle and vessel material is
17,500 psi. The maximum allowable working pressure
(Internal fillet weld throat p 0.530) of the design is 1,500 psig. See Fig. A-69 for all
nozzle and vessel dimensions.
≥ (0.7 t min p 0.525) The welded attachments do not qualify for the excep-
tion provided in PG-32 and must therefore comply
with PG-33 as follows.
As verified by the above demonstrations, the design is
proved to be in compliance with the requirements of Minimum required thickness for reinforcement consider-
Section I. ation:

PRv
Shell tr p
Sv − (1 − y) P
A-68
1,500 ⴛ 30
p
A boiler has an NPS 4 extra-strong pipe connection 17,500 − (1 − 0.4) ⴛ 1500
mounted as shown in Fig. A-68. The maximum allow-
able stress is 12,000 psi for the pipe material and p 2.711 in.
13,700 psi for the boiler shell material. The maximum
allowable working pressure of the boiler is 250 psig. P (0.5 dl1 − tn1)
Nozzle trn 1 and 4 p
See Fig. A-68 for pipe and shell dimensions. Sn − (1 − y) P

191
A-69 2001 SECTION I A-69

0.29487 in. min.

4.5 in. [See PG-27.3 and
PG-27.4 Note (7)]
4 in. extra 3.826 in.
strong pipe

Limit of reinforcement

WL1 = 3/8 in. 0.73717 in.

7/ in.
16

inside diameter
Wd = 1/4 in.
45 deg

30 in.

vessel
7.652 in. limit of
reinforcement

FIG. A-68 EXAMPLE FOR TYPICAL NOZZLE COMPUTATIONS

冢 2 + t + t冣 + 冢 2 + t + t冣
1,500 (0.5 ⴛ 4.5 − 0.875) d2 d3
p p
17,500 − (1 − 0.4) ⴛ 1500 n2 n3

p 0.124 in. 3.0 3.0

p + 1.0 + 3.25 + + 1.0 + 3.25
2 2
P (0.5 dl2 − tn2)
Nozzle trn 2 and 3 p
Sn − (1 − y) P p 11.5 in. > D1

1,500(0.5 ⴛ 5 − 1.0)
p
17,500 − (1 − 0.4) ⴛ 1500
The sum of the limits of reinforcement on the diagonal
p 0.136 in. between nozzles 3 and 4 is:

Check for overlapping limits:

The sum of the limits of reinforcement on the longitudi-
冢 2 + t + t冣 + 冢 2 + t + t冣
d3 d4
nal axis between nozzles 1 and 2, as permitted under p n3 n4

PG-36.2.2, is:
3.0 2.75
冢 冣 冢 冣
d d p + 1.0 + 3.25 + + 0.875 + 3.25
p 1 + tn1 + t + 2 + tn 2 + t 2 2
2 2
p 11.25 in. > D1
2.75 3.25
p + 0.875 + + 3.0 + 1.0 + 3.25
2 2

p 11.25 in. > D1 Each of the above conditions is greater than the center-
to-center distance, for the condition considered, between
The sum of the limits of reinforcement on the circumfer- the openings; therefore, the limits of reinforcement
ential axis between nozzles 2 and 3 is: overlap and the rule of PG-38.1 shall apply.

192
 APPENDIX Fig. A-69

d1 d2
+ n1 + t = 5.5 in. D1 = 9 in. + tn 2 + t = 7.25 in.
2 2

d11 = 41/2 in. d12 = 5 in.

tn1 = 7/
8 in. tn2 = 1 in.
d1 d2
D1 x = 4.304 in. D1 x = 4.695 in.
d1 + d2 d1 + d2
Limit of
reinforcement 21/2 in. (2.5 tn2)

WL1 = 11/8 in.

23/16 in. (2.5 tn1)
WL3 = 11/4 in.
Nozzle No. 1

Nozzle No. 2
Wd1 = 1 in. Wd3 = 11/4 in.

t = 31/4 in. Wd2 = 1 in.

Wd4 = 11/4 in.

CL

CL
3/ in. 3/
4 in.
inside diameter

d1 = 2.75 in. d2 = 3.0 in.

60 in.

vessel

WL2 = 1/2 in. WL4 = 1/2 in.

D1 = 9 in. D1 = 9 in.
d11 = 41/2 in.
d12 = 41/ 2 in. d12 = 5 in.

No. 1 No. 2 No. 1 Longitudinal

line

D2 = 61/2 in.
1/4
in.
= 8
No. 3
D3

d13 = 5 in.

30 deg 30 deg
No. 4 No. 4

d14 = 41/2 in. d14 = 41/2 in.

GENERAL NOTES:
(a) Nozzles 1 and 4 are identical dimensionally and nozzles 2 and 3 are identical dimensionally.
(b) This example was performed using computer software. The example was generated by performing the entire calculation without rounding
off during each step. Accuracy of the final results beyond three significant figures is not intended or required.

FIG. A-69 EXAMPLE FOR TYPICAL NOZZLE COMPUTATIONS A02

193
A-69 2001 SECTION I A-69

Nozzle 1 and 4 — area of reinforcement required in modification. To prevent any reinforcement available
the longitudinal plane: between the nozzles from being counted more than
once, the reinforcement limit is reduced such that the
Al 1 p (d1 + 2tn1) trF available reinforcement in the shell is divided and
attributed to either nozzle’s compensation in proportion
p (2.75 + 2 ⴛ 0.875) ⴛ 2.711 ⴛ 1.0 to its relative size. For nozzle 1, this limit is D1 [d1/ (d1
+ d2)]. The limit on the other side remains unchanged as
p 12.199 sq in. d1/2 + tn1 + t.

Nozzle 2 and 3 — area of reinforcement required in 冦 冧

A1 p t + D1 [d1/ (d1 + d2)] − d1/2 (t + Ftr)
the longitudinal plane:
p 冦3.25 + 9 [2.75/ (2.75 + 3.0)] − 4.5/2冧
Al 2 p (d2 + 2 tn2) trF
ⴛ (3.25 − 1.0 ⴛ 2.711)
p (3.0 + 2 ⴛ 1.0) ⴛ 2.711 ⴛ 1.0
p 2.860 sq in.
p 13.554 sq in.
A2 p 2 (tn1 − trn1) 2.5 tn1

Nozzle 2 and 3 — area of reinforcement required in p 2 (0.875 − 0.12424) ⴛ 2.5 ⴛ 0.875

the circumferential plane: p 3.285 sq in.

Ac2 p (d2 + 2tn2) trF A3 p 2 tn1 h

p 2 ⴛ 0.875 ⴛ 4.0
p (3.0 + 2 ⴛ 1.0) ⴛ 2.711 ⴛ 0.5
p 7.0 sq in.
p 6.777 sq in.
A4p WL12 + WL22

Nozzle 3 — area of reinforcement required in the p 1.1252 + 0.52

diagonal plane:
p 1.516 sq in.
Total area of available reinforcement provided by nozzle
Ad3 p (d3 + 2tn3) trF
1 in the longitudinal plane:
p (3.0 + 2 ⴛ 1.0) ⴛ 2.711 ⴛ 0.88
A1 + A2 + A3 + A41 + A42 p 14.660 sq in. ≥ Al1
p 11.928 sq in.
as required for demonstration of compliance with
Nozzle 4 — area of reinforcement required in the PG-33.
diagonal plane: Area of reinforcement provided in nozzle 2 in the
longitudinal plane:
Ad4 p (d4 + 2tn4) trF Since nozzle 2 has its limits of reinforcement restricted
on both sides by nozzle 1, the reduced limit of D1 [d2 /
p (2.75 + 2 ⴛ 0.875) ⴛ 2.711 ⴛ 0.88 (d1 + d2)] is applicable to both sides.

p 10.735 sq in.
冦 冧
dl2
A1 p 2 ⴛ D1 [d2 /(d1 + d2)] − (t − Ftr)
2
Area of reinforcement provided in nozzle 1 in the
冦 冧
5.0
longitudinal plane: p 2 ⴛ 9 [3.0/(2.75 + 3.0)] −
2
Due to the overlapping limits of reinforcement, the
equation for A1 (given in Fig. PG-33.1) will require ⴛ (3.25 − 1.0 ⴛ 2.711)

194
A-69 APPENDIX A-69

Total area of available reinforcement provided by nozzle

p 3.716 sq in. 2 or 3 in the circumferential plane:
A2 p 2 (tn2 − trn2) 2.5tn2
A1 + A2 + A3 + A4 p 24.081 sq in. ≥ Ac2
p 2 (1.0 − 0.136) ⴛ 2.5 ⴛ 1.0

p 4.322 sq in.
as required for demonstration of compliance with
PG-33.
A3 p 2tn2 h
Area of reinforcement provided by nozzle 3 in the
p 2 ⴛ 1.0 ⴛ 4.0 diagonal plane:
Although nozzle 1 does not lie exactly in the same
p 8.0 sq in.
plane as nozzles 3 and 4 and is slightly farther away,
A4 p WL32 + WL42 for simplicity the limit on both sides of nozzle 3 are
restricted to the reduced limit between nozzles 3 and 4.
p 1.252 + 0.52

冦 冧
dl3
p 1.812 sq in. A1 p 2 ⴛ D3 ⴛ [d3/(d3 + d4)] − (t − Ftr)
2

冦 冧
5.0
p 2 ⴛ 8.25 ⴛ [3.0/(3.0 + 2.75)] −
2
Total area of available reinforcement provided by nozzle
2 in the longitudinal plane: ⴛ (3.25 ⴛ 0.88 ⴛ 2.711)

p 5.281 sq in.

A1 + A2 + A3 + A4 p 17.850 sq in. ≥ Al 2 A2 p 2 (tn3 − trn3) 2.5tn3

p 2 (1.0 − 0.136) ⴛ 2.5 ⴛ 1.0
as required for demonstration of compliance with
PG-33. p 4.322 sq in.
Area of reinforcement provided in nozzle 2 or 3 in A3 p 2 tn3 h
the circumferential plane:
p 2 ⴛ 1.0 ⴛ 4.0

p 8.0 sq in.

冦 冧
dl2
A1 p t + D1 [d2 /(d2 + d3)] − (t − Ftr) A4 p WL 32 + WL42p 1.252 + 0.52
2
p 1.812 sq in.
冦 冧
5.0
p 3.25 + 9 [3.0/(3.0 + 3.0)] −
2
Total area of available reinforcement provided by nozzle
ⴛ (3.25 − 0.5 ⴛ 2.711) 3 in the diagonal plane:
p 9.947 sq in.
A1 + A2 + A3 + A4 p 19.415 sq in. ≥ Ad3
A2 p 2 (tn2 − trn2) 2.5tn2

p 2 (1.0 − 0.13554) ⴛ 2.5 ⴛ 1.0 as required for demonstration of compliance with PG-33.

p 4.3223 sq in.
Area of reinforcement provided in nozzle 4 in the
A3 p 2 tn2h
diagonal plane:
p 2 ⴛ 1.0 ⴛ 4.0

冦 冧
d4
p 8.0 sq in. A1 p t + D3 ⴛ [d4 /(d4 + d3)] − (t − Ftr)
2
2 2
A4 p WL3 + WL4
冦 冧
4.5
2 2 p 3.25 + 8.25 ⴛ [2.75/(2.75 + 3.0)] −
p 1.25 + 0.5 2

p 1.8125 sq in. ⴛ (3.25 − 0.88 ⴛ 2.711)

195
A-69 2001 SECTION I A-69

Total net area provided in the longitudinal plane between

p 4.275 sq in.
nozzles 1 and 2:
A2 p 2 (tn4 − trn4) 2.5 tn4

p 2 (0.875 − 0.124) ⴛ 2.5 ⴛ 0.875 nav + nan p 18.0625 sq in. ≥ nar as required for demon-
stration of compliance with PG-38.4
p 3.285 sq in.

A3 p 2 tn4 h Net area required in the circumferential plane between

p 2 ⴛ 0.875 ⴛ 4.0
nozzles 2 and 3:

p 7.0 sq in. nar p 0.7 Ftr D2

A4 p WL 32 + WL42 p 0.7 ⴛ 0.5 ⴛ 2.711 ⴛ 6.5
2 2
p 1.25 + 0.5 p 6.167 sq in.
p 1.516 sq in.
Net area provided in vessel wall:
Total area of available reinforcement provided by nozzle
4 in the diagonal plane: nav p [D2 − 0.5 (dl2 + dl3)]t

p [6.5 − 0.5 ⴛ (5 + 5)] ⴛ 3.25

A1 + A2 + A3 + A4 p 16.076 sq in. ≥ Ad4
p 4.875 sq in.

as required for demonstration of compliance with PG-33.

Net area provided in the nozzle wall fused to the
The rule of PG-38.4 for the minimum required net vessel wall:
cross-sectional area between any two finished openings
shall apply as follows. nan p Ttn2 Wd3 + tn2 Wd4 + tn3 Wd3 + tn3 Wd4

p 1.0 ⴛ 1.25 + 1.0 ⴛ 1.25 + 1.0 ⴛ 1.25

Net area required in longitudinal plane between nozzles + 1.0 ⴛ 1.25
1 and 2: p 5 sq in.

nar p 0.7 Ftr D1

Total net area provided in the circumferential plane
p 0.7 ⴛ 1.0 ⴛ 2.711 ⴛ 9 between nozzles 2 and 3:
p 17.078 sq in.
nav + nan p 9.875 sq in. ≥ nar as required for
demonstration of compliance with
Net area provided in vessel wall: PG-38.4
Net area required in the diagonal plane between nozzles
nav p [D1 − 0.5 (dl1 + dl2)] t 3 and 4:
p [9 − 0.5 ⴛ (4.5 + 5)] ⴛ 3.25
nar p 0.7 Ftr D3
p 13.812 sq in.
p 0.7 ⴛ 0.88 ⴛ 2.711 ⴛ 8.25

Net area provided in nozzle wall fused to vessel wall: p 13.776 sq in.
Net area provided in vessel wall:
nan p tn1Wd1 + tn1Wd2 + tn2Wd3 + tn2Wd4
nav p [D3 − 0.5 (dl3 + dl4)] t
p 0.875 ⴛ 1.0 + 0.875 ⴛ 1.0 + 1.0 ⴛ 1.25 +
1.0 ⴛ 1.25 p [8.25 − 0.5 ⴛ (5 + 4.5)] ⴛ 3.25
p 4.25 sq in. p 11.375 sq in.

196
A-69 APPENDIX A-69

Net area provided in the nozzle wall fused to the Strength of the welds:
vessel wall:
nan p tn3 Wd3 + tn3 Wd4 + tn4 Wd1 + tn4 Wd2
Fillet welds in shear
p 1.0 ⴛ 1.25 + 1.0 ⴛ 1.25 + 0.875 ⴛ 1.0
+ 0.875 ⴛ 1.0 p1⁄2 ␲ (WL3 + WL4)dl2(factor in PW-15.2) S
p 4.25 sq in.
p0.5 ⴛ 3.142 ⴛ (1.25 + 0.5) ⴛ 5 ⴛ 0.49 ⴛ 17,500

Total net area provided in the diagonal plane between p117,859 lb

nozzles 3 and 4: Groove welds in tension
nav + nan p 15.625 sq in. ≥ nar as required for p1⁄2 ␲ (Wd3 + Wd4)dl2(factor in PW-15.2)S
demonstration of compliance with
PG-38.4 p0.5 ⴛ 3.142 ⴛ (1.25 + 1.25) ⴛ 5 ⴛ 0.74 ⴛ 17,500
Nozzles 1 and 4 — The required minimum strength p254,273 lb
to be provided by the combined load-carrying elements
through each load-carrying path (see PG-37 and PW-15): The combined strength of path number 3 equals 372,132
lb ≥ W as required for demonstration of compliance
W p (A − A1) Sv with PG-37 and PW-15.
p (12.199 − 2.860) ⴛ 17,500

p 163,431 lb Nozzles 1 and 4 — Verification of minimum weld

sizing as required by PW-16.1 and Fig. PW-16.1,
sketch (f):
Strength of the welds:

Required per Fig. PW-16.1, sketch (f):

Fillet welds in shear
t1 + t2 ≥ 1.25tmin
p1⁄2 ␲ ⴛ (WL1 + WL2) dl1 (factor in PW-15.2) S
tc ≥ 0.25
p0.5 ⴛ 3.142 ⴛ (1.125 + 0.5) ⴛ 4.5 ⴛ 0.49 ⴛ 17,500
t1 ≥ 0.25
p98,495 lb
t2 ≥ 0.25
Groove welds in tension
Actual per Fig. A-69:
p1⁄2 ␲ (Wd1 + Wd2) dl1 (factor in PW-15.2) S

p0.5 ⴛ 3.142 ⴛ (1.0 + 1.0) ⴛ 4.5 ⴛ 0.74 ⴛ 17,500 t1 p WL1 sin 45°

p183,076 lb p 1.125 ⴛ 0.707

p 0.795 in.
The combined strength equals 281,571 lb ≥ W as
required for demonstration of compliance with PG-37 t2 p Wd1 + Wd2
and PW-15.
p 1.0 + 1.0
Nozzles 2 and 3 — The required minimum strength p 2 in.
of the welds (see PG-37 and PW-15): tc p WL2 sin 45°

p 0.5 ⴛ 0.7071
W p (A − A1) Sv
p 0.354 in.
p (13.544 − 3.715) ⴛ 17,500

p 172,177 lb tmin p 0.75 in. (based on PW-16.2)

197
A-69 2001 SECTION I A-71

Verification: 1,500 lb
7/ in.
8 960 lb
11/2 in. 11/8 in. 2 in.
(t1 + t2 p 2.795) ≥ (1.25tmin p 0.937)

3 in. 4 in.
(tc p 0.354) ≥ 0.25
4 in. O.D. 4 in. O.D.
× 0.300 in. × 0.300 in.
(t1 p 0.795) ≥ 0.25
FIG. A-71 FIG. A-72
(t2 p 2) ≥ 0.25
11/2 in.
Nozzles 2 and 3 — Verification of minimum weld
440 lb
sizing as required by PW-16.1 and Fig. PW-16.1, 3 in. R
sketch (f):
2 in.
21/2 in.
11/4 in.
Required per Fig. PW-16.1, sketch (f): 31/4 in. O.D.
× 0.375 in. 2 in. O.D.
× 0.300 in. 3/
4 in.
t1 + t2 ≥ 1.25tmin
1,200 lb
750 lb
tc ≥ 0.25
FIG. A-73 FIG. A-74
t1 ≥ 0.25

FIGS. A-71—A-74 TYPES OF STRUCTURAL

t2 ≥ 0.25
ATTACHMENTS TO TUBES

Actual per Fig. A-69:

t1 p WL3 sin 45°

As verified by the above demonstrations, the design is
p 1.25 ⴛ 0.7071 proved to be in compliance with the requirements of
p 0.884 in. Section I.

t2 p Wd3 + Wd4
p 1.25 + 1.25
EXAMPLES OF COMPUTATION OF
p 2.5 in. ALLOWABLE LOADING ON
STRUCTURAL ATTACHMENTS TO
tc p WL4 sin 45°
TUBES
p 0.5 ⴛ 0.707
A-71
p 0.354
A tube is suspended by a welded attachment with
the loads and dimensions as shown in Fig. A-71. This
tmin p 0.75 in. (based on PW-16.2)
is a condition of direct radial loading on the tube.
The allowable lug loading is calculated for the follow-
Verification:
ing conditions:
material p SA-213-T22
(t1 + t2 p 3.384) ≥ (1.25tmin p 0.937) MAWP p 2258 psi
(tc p 0.354) ≥ 0.25 T p 800°F
D p 4.0 in.
(t1 p 0.884) ≥ 0.25 t p 0.30 in.
1
(t2 p 2.5) ≥ 0.25 ⁄4 in. thick lug

198
A-71 APPENDIX A-72

7 deg attachment angle Actual load:

Sa p 15,000 psi
S p 15,000 psi W p 1,500 lb (Tension)
St p 2.0 Sa − S p 15,000 psi L p 1,500 lb/3 in. p 500 lb/in. < 650 lb/in.
From Table PW-43.1, K p 1.07
From Fig. PW-43.1 or PW-43.2.1 or PW-43.2.2 The loading indicated is therefore within the values
allowed by the chart in Fig. PW-43.1.
X p D/t2 p 44.4

A-72
Compression Lf p 0.0326 A load is supported on a rubbing strip welded to a
Tension Lf p 0.0405 tube, as shown in Fig. A-72. This problem illustrates
a condition where the load is not applied on the center
La p K (Lf)S of welded attachment.
The allowable lug loading is calculated for the same
conditions given in example A-71:
Compression La p (1.07)(0.0326)(15,000)
Compression La p (1.07)(0.0326)(15,000)
p 523 lb/in.
p 523 lb/in.
Tension La p (1.07)(0.0405)(15,000) Tension La p (1.07)(0.0405)(15,000)
p 650 lb/in. p 650 lb/in.

199
A-72 2001 SECTION I A-74

Allowable unit load P: Actual:

W p 440 lb
D 4
p p 44.4
t2 0.3002 6 ⴛ 440 ⴛ 1.5
Lp
Pp660 lb/in. tension; 555 lb/in. compression 22

Actual unit load: p 990 lb/in. compression or tension

The actual loading does not exceed values of allow-

W p 960 lb able loading.

960 (6 ⴛ 960 ⴛ 0.875) A-73.2 To determine the maximum allowable loading

Pp ± p 240 ± 315 on structural attachments to tubes, a test may be con-
4 22
ducted on a full-size section of tube with attachment.
p 555 lb/in. compression; 75 lb/in. tension The test may be considered as meeting the Code
The actual loading does not exceed values of allow- requirements provided:
able loading.
A-73.2.1 The loading applied to the test specimen
is at least equivalent to the design loading, and at the
A-73 same time the tube is subjected to a hydrostatic pressure
corresponding to design conditions.
A-73.1 A load is supported from a vertical tube with
a welded bracket attachment as shown in Fig. A-73. A-73.2.2 The test is conducted in accordance with
This example illustrates a condition of eccentric loading the requirements of A-22 with the exception that the
where the direct loading is not additive. hydrostatic pressure shall be held at expected design
The allowable lug loading is calculated for the follow- pressure, and the loading on the support shall be
ing conditions: increased until permanent set occurs.
material p SA-213-T22 A-73.2.3 The maximum load P, allowed on the
MAWP p 3722 psi attachment at or below the pressure corresponding to
T p 800°F the hydrostatic pressure, is given by the following
D p 3.25 in. formula:
t p 0.375 in.
1
⁄4 in. thick lug HS
Pp
10 deg attachment angle E
Sa p 15,000 psi
S p 15,000 psi where
St p 2.0 Sa − S p 15,000 psi P p maximum allowable load on attachment, lb
From Table PW-43.1, K p 1.07 H p test load at the proportional limit of the struc-
ture, lb
From Fig. PW-43.1, PW-43.2.1, or PW-43.2.2 S p working stress permitted in Table 1A of Section
II, Part D, for the tube material at the design
X p D/t2 p 23.11 temperature that in no case shall be taken at
less than 700°F, psi
Compression Lf p 0.0637 E p average proportional limit of the tube mate-
Tension Lf p 0.090 rial, psi

La p K (L f)S

Compression La p (1.108)(0.0637)(15,000) A-74

p 1,058 lb/in. A superheater section is supported by welded attach-
ment to the short-radius return bend section as shown
Tension La p (1.108)(0.090)(15,000) p 1,495 lb/in. in Fig. A-74. This example illustrates a condition where

200
A-74 APPENDIX A-100.4.3

a direct and eccentric load is applied to a bent tube PREHEATING

section.
The allowable lug loading is calculated for the follow- A-100
ing conditions: A-100.1 Preheating may be employed during welding
material p SA-213-T22 to assist in completion of the welded joint. The need
MAWP p 5,087 psi for and the temperature of preheat are dependent on
T p 700°F a number of factors such as chemical analysis, degree of
D p 2.0 in. restraint of the parts being joined, elevated temperature
t p 0.30 in. mechanical properties, and material thicknesses. Manda-
1 tory rules for preheating are, therefore, not given in
⁄4 in. thick lug
15 deg attachment angle this Section except as required in Table PW-39. As a
Sa p 15,000 psi general guide, some minimum temperatures for pre-
S p 15,000 psi heating are given in A-100.4. It is cautioned that
St p 2.0 Sa − S p 15,000 psi the preheating temperatures listed in A-100.4 do not
necessarily ensure satisfactory completion of the welded
From Table PW-43.1, K p 1.16 joint. Requirements for individual materials within the
From Fig. PW-43.1, PW-43.2.1, or PW-43.2.2 P-Number listing may have preheating requirements
more or less restrictive than this general guide. The
Welding Procedure Specification for the material being
X p D/t2 p 22.2
welded shall specify the minimum preheating require-
ments described in the welding procedure qualification
requirements of Section IX.
Compression L f p 0.0664
Tension L f p 0.0948 A-100.2 The heat of welding may assist in main-
taining preheat temperatures after the start of welding
For bend:
and, for inspection purposes, temperature measurements
may be made near the weld. The method or extent of
X p (Bend dia)/t2 p 6/0.32 p 66.6 application of preheat is not, therefore, specifically
given. Normally, when materials of two different P-
Number groups are joined by welding, the preheat used
From Fig. PW-43.1 or Eqs. PW-43.2.1 or PW-43.2.2
will be that of the material with the higher preheat
Compression L f p 0.0215
specified on the Welding Procedure Specification.
Tension L f p 0.0257
A-100.3 Thicknesses referred to are nominal at the
weld for the parts to be joined.
La p K(⌺Lf) 9
A-100.4 Minimum Temperatures for Preheating
A-100.4.1 P-No. 1, Group No. 1, 2, 3. 175°F
Compression L a p (1.16)(0.0664 + 0.0215)(15,000) (79°C) for material that has both a specified maximum
p 1,529 lb/in. carbon content in excess of 0.30% and a thickness at
Tension L a p (1.16)(0.0948 + 0.0257)(15,000) the joint in excess of 1 in. (25 mm); 50°F (10°C) for
p 2,096 lb/in. all other materials in this grouping.

A-100.4.2 P-No. 3, Group No. 1, 2, 3. 175°F

Actual unit load: (79°C) for material that has either a specified minimum
tensile strength in excess of 70,000 psi (480 MPa) or
750 6 ⴛ 1,200 ⴛ 0.75 a thickness at the joint in excess of 5⁄8 in. (16 mm);
P p ±
2.5 2.52 50°F (10°C) for all other materials in this grouping.
p 300 ± 864 p 1,164 lb/in. compression; 564 lb/in.
A-100.4.3 P-No. 4, Group No. 1, 2. 250°F (79°C)
tension
for material that has either a specified minimum tensile
strength in excess of 60,000 psi (410 MPa) or a
The actual applied load is less than the values allowed thickness at the joint in excess of 1⁄2 in. (13 mm);
by the chart in Fig. PW-43.1. 50°F (10°C) for all other materials in this grouping.

201
 A-100.4.4 2001 SECTION I A-250.3.2

A-100.4.4 P-No. 5A, B, C. 400°F (204°C) for Z1 p (SE + P) / (SE −P)

material that has either a specified minimum tensile Z2 p [(R + t) / R ]2 p (Ro / R)2
strength in excess of 60,000 psi (410 MPa) or has t p minimum thickness of shell plates in weakest
both a specified minimum chromium content above course, in. (mm)
6.0% and a thickness at the joint in excess of 1⁄2 in. R p inside radius of the weakest course of the shell,
(13 mm); 300°F (149°C) for all other materials in this in. (mm)
grouping. Ro p outside radius of the weakest course of the shell,
in. (mm)
A-100.4.5 P-No. 6, Group No. 1, 2, 3. 400°F
(204°C).
NOTE: Restrictions of PG-27.2.2 also apply to this paragraph.
A-100.4.6 P-No. 7, Group No. 1, 2. None.
ROUNDED INDICATION CHARTS
A-100.4.7 P-No. 8, Group No. 1, 2. None.
A-250 Acceptance Standard for
A-100.4.10 P-No. 10A, Group No. 1. 175°F Radiographically Determined Rounded
(79°C). Indications in Welds
A-100.4.11 P-No. 10E, Group No. 5. 300°F A-250.1 Applicability of These Standards. These
(149°C) with interpass maintained between 350°F and standards are applicable to ferritic, austenitic, and non-
450°F (177°C and 232°C). ferrous materials.

A-250.2 Terminology
MAXIMUM ALLOWABLE WORKING
A-250.2.1 Rounded Indications. Indications with
PRESSURES — THICK SHELLS a maximum length of three times the width or less on
01 A-125 Shells for Internal Pressure the radiograph are defined as rounded indications. These
A02 indications may be circular, elliptical, conical, or irregu-
When the thickness of the shell exceeds one-half of lar in shape and may have tails. When evaluating the
the inside radius, the required thickness and maximum size of an indication, the tail shall be included. The
allowable working pressure on the cylindrical shell of indication may be from any imperfection in the weld,
a boiler or drum shall be determined by the following such as porosity, slag, or tungsten.
formulas:
A-250.2.2 Aligned Indications. A sequence of
冪 Z1 − 1
t p (冪 Z1 − 1) R p 冢 冪 Z1
冣 Ro four or more rounded indications shall be considered
to be aligned when they touch a line parallel to the
length of the weld drawn through the center of the
or
two outer rounded indications.

Z2 − 1
P p SE A-250.2.3 Thickness t. t is the thickness of the
Z2 + 1
weld, of the pressure–retaining material, or of the
thinner of the sections being joined, whichever is least.
where If a full penetration weld includes a fillet weld, the
P p maximum allowable working pressure, psi thickness of the fillet weld throat shall be included in t.
(kPa)
S p maximum allowable working unit stress, psi
(kPa), taken from Table 1A of Section II, Part D A-250.3 Acceptance Criteria
E p efficiency of longitudinal joints or of ligaments A-250.3.1 Image Density. Density within the im-
between openings: age of the indication may vary and is not a criterion
for fusion welded jointspefficiency specified for acceptance or rejection.
in PG-27.4, Note 1
for seamless shellsp100% (unity) A-250.3.2 Relevant Indications (See Table 1
for ligaments between openings, the effi- for Examples). Only those rounded indications which
ciency shall be calculated by the rules given in exceed the following dimensions shall be considered
PG-52 relevant.

202
A-250.3.2 APPENDIX A-250.3.8

TABLE 1 size of any indication shall be 1⁄4t, or 5⁄32 in. (4 mm),

MAXIMUM PERMISSIBLE SIZE OF whichever is smaller; except that an isolated indication
ROUNDED INDICATION separated from an adjacent indication by 1 in. (25 mm)
(Examples Only)
or more may be 1⁄3t, or 1⁄4 in. (6 mm), whichever is
Customary Units less. For t greater than 2 in. (51 mm) the maximum
permissible size of an isolated indication shall be in-
Maximum Size of
Acceptable Rounded Maximum Size creased to 3⁄8 in. (10 mm).
Indication, in. of Nonrevelant
Thickness Indication,
t, in. Random Isolated in.
A-250.3.4 Aligned Rounded Indications. Aligned
rounded indications are acceptable when the summation
Less than 1⁄8 1
⁄4t 1
⁄3t 1
⁄10t of the diameters of the indications is less than t in a
1
⁄8 0.031 0.042 0.015
3 length of 12t. (See Fig. 1.) The length of groups of
⁄16 0.047 0.063 0.015
1
⁄4 0.063 0.083 0.015 aligned rounded indications and the spacing between
5
⁄16 0.078 0.104 0.031 the groups shall meet the requirements of Fig. 2.
3
⁄8 0.091 0.125 0.031
7
⁄16 0.109 0.146 0.031
1
⁄2 0.125 0.168 0.031
A-250.3.5 Spacing. The distance between adjacent
9
⁄16 0.142 0.188 0.031 rounded indications is not a factor in determining
5
⁄8 0.156 0.210 0.031 acceptance or rejection, except as required for isolated
11
⁄16 0.156 0.230 0.031 indications or groups of aligned indications.
3
⁄4 to 2 incl. 0.156 0.250 0.031
Over 2 0.156 0.375 0.063
A-250.3.6 Rounded Indication Charts. The
SI Units rounded indications characterized as imperfections shall
Maximum Size of not exceed that shown in the charts.
Acceptable Rounded Maximum Size The charts in Fig. 3.1 through Fig. 3.6 illustrate
Indication, mm of Nonrevelant
various types of assorted, randomly dispersed, and
Thickness Indication,
t, mm Random Isolated mm clustered rounded indications for different weld thick-
nesses greater than 1⁄8 in. (3.2 mm). These charts
1 1 1
Less than 3.18 ⁄4t ⁄3t ⁄10t represent the maximum acceptable concentration limits
3.18 0.79 1.07 0.38
4.76 1.19 1.60 0.38
for rounded indications.
6.35 1.60 2.11 0.38 The chart for each thickness range represents full-
7.94 1.98 2.64 0.79 scale 6 in. (152 mm) radiographs, and shall not be
9.52 2.31 3.18 0.79 enlarged or reduced. The distributions shown are not
11.11 2.77 3.71 0.79 necessarily the patterns that may appear on the radio-
12.70 3.18 4.27 0.79
14.29 3.61 4.78 0.79 graph, but are typical of the concentration and size of
15.88 3.96 5.33 0.79 indications permitted.
17.46 3.96 5.84 0.79
19.05 to 50.80 incl. 3.96 6.35 0.79
Over 50.80 3.96 9.53 1.60
A-250.3.7 Weld Thickness t Less Than 1⁄8 in.
(3.2 mm). For t less than 1⁄8 in. (3.2 mm) the maximum
number of rounded indications shall not exceed 12 in
a 6 in. (152 mm) length of weld. A proportionally
fewer number of indications shall be permitted in welds
1
⁄10 t for t less than 1⁄8 in. (3.2 mm) less than 6 in. in length.
1
⁄64 in. (0.4 mm) for t 1⁄8 in. to 1⁄4 in. (6 mm),
inclusive A-250.3.8 Clustered Indications. The illustrations
1
⁄32 in. (0.8 mm) for t 1⁄4 in. (6 mm) to 2 in. for clustered indications show up to four times as
(51 mm), inclusive many indications in a local area, as that shown in the
1 illustrations for random indications. The length of an
⁄16 in. (1.6 mm) for t greater than 2 in.
(51 mm) acceptable cluster shall not exceed the lesser of 1 in.
or 2t. Where more than one cluster is present, the sum
A-250.3.3 Maximum Size of Rounded Indication of the lengths of the clusters shall not exceed 1 in.
(See Table 1 for Examples). The maximum permissible (25 mm) in a 6 in. (152 mm) length of weld.

203
 Fig. 1

L1 Lx

L2
GENERAL NOTE: Sum of L1 to Lx shall be less than t in a length of 12 t.

FIG. 1 ALIGNED ROUNDED INDICATIONS

204
2001 SECTION I

L1 3L2 3L3 L3 3L3 L4

Maximum Group Length Minimum Group Spacing

L = 1/4 in. (6 mm) for t less than 3/4 in. (19 mm) 3L where L is the length of the
L = 1/3 t for t 3/4 in. (19 mm) to 21/4 in. (57 mm) longest adjacent group being
L = 3/4 in. (19 mm) for t greater than 21/4 in. (57 mm) evaluated.

GENERAL NOTE: Sum of the group lengths shall be less than t in a length of 12 t.

FIG. 2 GROUPS OF ALIGNED ROUNDED INDICATIONS

Fig. 2
A-260 APPENDIX A-260.4

GENERAL NOTE: Typical concentration and size permitted in any 6 in. (152 mm) length of weld

(a) Random Rounded Indications

1 in. (25 mm) 1 in. (25 mm)

(b) Isolated Indication (c) Cluster

(Maximum size per Table I)

FIG. 3.1 CHARTS FOR t 1⁄8 in. (3.2 mm) TO 1⁄4 in. (6 mm), INCLUSIVE

METHODS FOR MAGNETIC operation, he may be certified as being qualified only

PARTICLE EXAMINATION (MT) for one or more of these operations.
A-260 A-260.3 Evaluation of Indications. Indications will 01
be revealed by retention of magnetic particles. All such
A-260.1 Scope. This Appendix provides for proce-
indications are not necessarily imperfections, however,
dures that shall be followed whenever magnetic particle
since excessive surface roughness, magnetic permeabil-
examination is required by PG-93. The detailed exami-
ity variations (such as at the edge of heat affected
nation method of Article 7 of Section V shall be used
zones), etc., may produce similar indications.
with the acceptance criteria specified in this Appendix.
An indication of an imperfection may be larger than
Magnetic particle examination shall be performed in
the imperfection that causes it; however, the size of
accordance with a written procedure, certified by the
the indication is the basis for acceptance evaluation.
Manufacturer to be in accordance with the requirement
Only indications that have any dimension greater than
of T-150 of Section V. 1
⁄16 in. shall be considered relevant.
(a) A linear indication is one having a length greater
than three times the width.
A-260.2 Certification of Personnel. The Manufac-
(b) A rounded indication is one of circular or elliptical
turer shall certify that each magnetic particle examiner
shape with a length equal to or less than three times
meets the following requirements.
its width.
(a) The examiner has vision, with correction if neces-
(c) Any questionable or doubtful indications shall
sary, to enable him to read a Jaeger Type No. 2
be reexamined to determine whether or not they are
Standard Chart at a distance of not less than 12 in.
relevant.
and is capable of distinguishing and differentiating
contrast between colors used. These capabilities shall A-260.4 Acceptance Standards. All surfaces to be 01
be checked annually. examined shall be free of:
(b) The examiner is competent in the techniques of (a) relevant linear indications;
the magnetic particle examination method for which (b) relevant rounded indications greater than 3⁄16 in.
he is certified, including making the examination and (4.8 mm); and
interpreting and evaluating the results, except that where (c) four or more relevant rounded indications in a
the examination method consists of more than one line separated by 1⁄16 in. (1.6 mm) or less, edge to edge.

205
 A-270 2001 SECTION I A-301.1

METHODS FOR LIQUID (b) relevant rounded indications greater than 3⁄16 in.
PENETRANT EXAMINATION (PT) (4.8 mm); and
(c) four or more relevant rounded indications in a
NOTE: Satisfactory application of this method of examination requires
special skills in the techniques involved and in interpreting the
line separated by 1⁄16 in. (1.6 mm) or less, edge to edge.
results. The requirements specified herein presume application by
suitably experienced personnel.

A-270
A-270.1 Scope. This Appendix provides for proce- QUALITY CONTROL SYSTEM
dures that shall be followed whenever liquid penetrant A-300
examination is required by PG-93. The detailed exami-
nation method of Article 6 of Section V shall be used A-301 General
with the acceptance criteria specified in this Appendix. A-301.1 Quality Control System. The Manufacturer
Liquid penetrant examination shall be performed in or assembler shall have and maintain a quality control
accordance with a written procedure, certified by the system which will establish that all Code requirements,
Manufacturer to be in accordance with the requirement including material, design, fabrication, examination (by
of T-150 of Section V. the Manufacturer) and inspection of boilers and boiler
A-270.2 Certification of Personnel. The Manufac- parts (by the Authorized Inspector), will be met. Pro-
turer shall certify that each liquid penetrant examiner vided that Code requirements are suitably identified,
meets the following requirements. the system may include provisions for satisfying any
(a) The examiner has vision, with correction if neces- requirements by the Manufacturer or user which exceed
sary, to enable him to read a Jaeger Type No. 2 minimum Code requirements and may include provi-
Standard Chart at a distance of not less than 12 sions for quality control of non-Code work. In such
in. (305 mm) and is capable of distinguishing and systems, the Manufacturer may make changes in parts
differentiating contrast between colors used. These capa- of the system which do not affect the Code requirements
bilities shall be checked annually. without securing acceptance by the Authorized Inspec-
(b) The examiner is competent in the techniques of tor. Before implementation, revisions to quality control
the liquid penetrant examination method for which systems of Manufacturers and Assemblers of safety
he is certified, including making the examination and and safety relief valves shall have been found acceptable
interpreting and evaluating the results, except that where to an ASME designee if such revisions affect Code
the examination method consists of more than one requirements.
operation, he may be certified as being qualified only The system that the Manufacturer or assembler uses
for one or more of these operations. to meet the requirements of this Section must be one
suitable for his own circumstances. The necessary scope
01 A-270.3 Evaluation of Indications. An indication and detail of the system shall depend on the complexity
of an imperfection may be larger than the imperfection of the work performed and on the size and complexity
that causes it; however, the size of the indication is of the Manufacturer’s (or assembler’s) organization. A
the basis for acceptance evaluation. Only indications written description of the system the Manufacturer or
that have any dimension greater than 1⁄16 in. (1.6 mm) assembler will use to produce a Code item shall be
shall be considered relevant. available for review. Depending upon the circumstances,
(a) A linear indication is one having a length greater the description may be brief or voluminous.
than three times the width. The written description may contain information of
(b) A rounded indication is one of circular or elliptical proprietary nature relating to the Manufacturer’s (or
shape with a length equal to or less than three times assembler’s) processes. Therefore, the Code does not
its width.
require any distribution of this information, except for
(c) Any questionable or doubtful indications shall
the Authorized Inspector or ASME designee.
be reexamined to determine whether or not they are
It is intended that information learned about the
relevant.
system in connection with evaluation will be treated
01 A-270.4 Acceptance Standards. All surfaces to be as confidential and that all loaned descriptions will be
examined shall be free of: returned to the Manufacturer upon completion of the
(a) relevant linear indications; evaluation.

206
Fig. 3.2 APPENDIX Fig. 3.3

GENERAL NOTE: Typical concentration and size permitted in any 6 in. (152 mm) length of weld

(a) Random Rounded Indications

1 in. (25 mm) 1 in. (25 mm)

(b) Isolated Indication (c) Cluster

(Maximum size per Table I)

FIG. 3.2 CHARTS FOR t OVER 1⁄4 in. (6 mm) TO 3⁄8 in. (10 mm), INCLUSIVE

GENERAL NOTE: Typical concentration and size permitted in any 6 in. (152 mm) length of weld

(a) Random Rounded Indications

1 in. (25 mm) 1 in. (25 mm)

(b) Isolated Indication (c) Cluster

(Maximum size per Table I)

FIG. 3.3 CHARTS FOR t OVER 3⁄8 in. (10 mm) TO 3⁄4 in. (19 mm), INCLUSIVE

207
A-302 2001 SECTION I A-302.5

GENERAL NOTE: Typical concentration and size permitted in any 6 in. (152 mm) length of weld.

(a) Random Rounded Indications

1 in. (25 mm) 1 in. (25 mm)

(b) Isolated Indication (c) Cluster

(Maximum size per Table 1)

FIG. 3.4 CHARTS FOR t OVER 3⁄4 in. (19 mm) TO 2 in. (51 mm), INCLUSIVE

A-302 Outline of Features to Be Included in to time to alter, whatever form of organization the
the Written Description of the Quality Manufacturer considers appropriate for its Code work.
Control System
A-302.3 Drawings, Design Calculations, and Speci-
The following is a guide to some of the features fication Control. The Manufacturer’s or assembler’s
that should be covered in the written description of quality control system shall provide procedures which
the quality control system and that is equally applicable will assure that the latest applicable drawings, design
to both shop and field work. calculations, specifications and instructions, required by
the Code, as well as authorized changes, are used for
A-302.1 Authority and Responsibility. The authority
manufacture, assembly, examination, inspection, and
and responsibility of those in charge of the quality
testing.
control system shall be clearly established. Persons
performing quality control functions shall have sufficient A-302.4 Material Control. The Manufacturer or
and well-defined responsibility, the authority, and the assembler shall include a system of receiving control
organizational freedom to identify quality control prob- that will insure that the material received is properly
lems and to initiate, recommend, and provide solutions. identified and has documentation, including required
material certifications or material test reports, to satisfy
A-302.2 Organization. An organization chart show- Code requirements as ordered. The material control
ing the relationship between management and engi- system shall insure that only the intended material is
neering, purchasing, manufacturing, field assembling, used in Code construction.
inspection, and quality control, is required to reflect
the actual organization. The purpose of this chart is A-302.5 Examination and Inspection Program. The
to identify and associate the various organizational Manufacturer’s quality control system shall describe
groups with the particular function for which they are the fabrication operations, including examinations, suf-
responsible. The Code does not intend to encroach on ficiently to permit the Authorized Inspector to determine
the Manufacturer’s right to establish, and from time at what stages specific inspections are to be performed.

208
A-302.6 APPENDIX A-302.11

GENERAL NOTE: Typical concentration and size permitted in any 6 in. (152 mm) length of weld.

(a) Random Rounded Indications

1 in. (25 mm) 1 in. (25 mm)

(b) Isolated Indication (c) Cluster

(Maximum size per Table I)

FIG. 3.5 CHARTS FOR t OVER 2 in. (51 mm) TO 4 in. (102 mm), INCLUSIVE

A-302.6 Correction of Nonconformities. There shall A-302.9 Heat Treatment. The quality control system
be a system agreed upon with the Authorized Inspector shall provide controls to assure that heat treatments as
for correction of nonconformities. A nonconformity is required by the rules of this Section are applied. Means
any condition that does not comply with the applicable shall be indicated by which the Authorized Inspector
rules of this Section. Nonconformities must be corrected can satisfy himself that these Code heat treatment
or eliminated in some way before the completed compo- requirements are met. This may be by review of furnace
nent can be considered to comply with this Section. time–temperature records or by other methods as appro-
priate.
A-302.7 Welding. The quality control system shall
include provisions for indicating that welding conforms
A-302.10 Calibration of Measurement and Test
to requirements of Section IX as supplemented by this
Equipment. The Manufacturer or assembler shall have
Section. Manufacturers intending to use AWS Standard
a system for the calibration of examination, measuring,
Welding Procedures shall describe control measures
and test equipment used in fulfillment of requirements
used to assure that the welding meets the requirements
of this Section.
of this Section (see PW-1.2) and Section IX.

A-302.8 Nondestructive Examination. The quality A-302.11 Records Retention. The Manufacturer or
control system shall include provisions for identifying assembler shall have a system for the maintenance of
nondestructive examination procedures the Manufacturer radiographs and Manufacturers’ Data Reports as re-
will apply to conform with requirements of this Section. quired by this Section.

209
Fig. 3.6 2001 SECTION I

GENERAL NOTE: Typical concentration and size permitted in any 6 in. (152 mm) length of weld.

(a) Random Rounded Indications

1 in. (25 mm) 1 in. (25 mm)

(b) Isolated Indication (c) Cluster

(Maximum size per Table I)

FIG. 3.6 CHARTS FOR t OVER 4 in. (102 mm)

210
A-302.12 APPENDIX A-314

A-302.12 Sample Forms. The forms used in the A-310 ACCEPTANCE OF TESTING
quality control system and any detailed procedures for LABORATORIES AND
their use shall be available for review. The written AUTHORIZED OBSERVERS FOR
description shall make necessary references to these CAPACITY CERTIFICATION OF
forms. SAFETY AND SAFETY RELIEF
VALVES
A-302.13 Inspection of Boilers and Boiler Parts
A-311 Scope
A-302.13.1 Inspection of boilers and boiler parts
shall be by the Authorized Inspector described in PG-91. These rules cover the requirements for ASME accept-
ance of testing laboratories and Authorized Observers
A-302.13.2 The written description of the quality for conducting capacity certification tests of safety and
control system shall include reference to the Authorized safety relief valves.
Inspector.

A-[Link] The Manufacturer (or assembler) A-312 Test Facilities and Supervision
shall make available to the Authorized Inspector at the
The tests shall be conducted at a place where the
Manufacturer’s plant (or construction site) a current
testing facilities, methods, procedures, and person super-
copy of the written description or the applicable quality
vising the tests (Authorized Observer) meet the applica-
control system.
ble requirements of ASME PTC 25-1994, Pressure
Relief Devices. The tests shall be made under the
A-[Link] The Manufacturer’s quality control
supervision of and certified by the Authorized Observer.
system shall provide for the Authorized Inspector at
The testing facilities, methods, procedures, and the
the Manufacturer’s plant to have access to all drawings,
qualifications of the Authorized Observer shall be sub-
calculations, specifications, procedures, process sheets,
ject to the acceptance of the ASME Boiler and Pressure
repair procedures, records, test results, and any other
Vessel Committee on recommendation of an ASME
documents as necessary for the Inspector to perform his
designee. Acceptance of the testing facility is subject
duties in accordance with this Section. The Manufacturer
to review within each 5 year period. The testing labora-
may provide such access either to his own files of
tory shall have available for reference a copy of ASME
such documents or by providing copies to the Inspector.
PTC 25-1994 and Section I.
A-302.14 Inspection of Safety and Safety Relief
Valves A-313 Acceptance of Testing Facility
A-302.14.1 Inspection of safety and safety relief
Before recommendation is made to the ASME Boiler
valves shall be by designated representative of the
and Pressure Vessel Committee on the acceptability of
ASME, as described in PG-73.3.
a testing facility, an ASME designee shall review the
A-302.14.2 The written description of the quality applicant’s quality control system and testing facility,
control system shall include reference to the ASME and shall witness test runs. Before a favorable recom-
designee. mendation can be made to the Committee, the testing
facility must meet all applicable requirements of ASME
A-[Link] The valve Manufacturer (or assem- PTC 25-1994. Uncertainty in final flow measurement
bler) shall make available to the ASME designee at results shall not exceed ±2%. To determine the uncer-
the Manufacturer’s plant a current copy of the written tainty in final flow measurements, the results of flow
description of the applicable quality control system. tests on an object tested at the applicant’s testing
laboratory will be compared to flow test results on
A-[Link] The valve Manufacturer’s (or as- the same object tested at the National Board Testing
sembler’s) quality control system shall provide for Laboratory.
the ASME designee to have access to all drawings,
calculations, specifications, procedures, process sheets,
A-314 Quality Control System of Testing
repair procedures, records, test results, and any other
Laboratory
documents as necessary for the designee to perform his
duties in accordance with this Section. The Manufacturer The applicant shall prepare a Quality Control Manual
may provide such access either to his own files of describing his quality control system which shall clearly
such documents or by providing copies to the designee. establish the authority and responsibility of those in

211
A-314 2001 SECTION I A-316

charge of the quality control system. The manual shall (b) The devices tested at the applicant’s facility
include a description of the testing facility, testing will then be tested at the National Board Testing
arrangements, pressure, size and capacity limitations, Laboratory in Columbus, Ohio, to confirm the test
and the testing medium used. An organization chart results obtained. Agreement between the results of the
showing the relationship among the laboratory personnel two laboratories shall be within ±2%. The purpose of
is required to reflect the actual organization. comparing test results at the two laboratories is not
The Quality Control Manual shall include, as a only to check procedures but also all test instruments
minimum, the applicable requirements of this Section and equipment of the applicant’s facility over the
and ASME PTC 25-1994, including but not limited to, a capacity and pressure range proposed. Since the capabili-
description of the Quality Control Manual and document ties of each laboratory are different, no specific number
control, the procedure to be followed when conducting of tests can be predetermined. The number will be in
tests, the methods by which test results are to be accordance with the flow capability and measurement
calculated, how test instruments and gages are to be techniques available at the laboratory being evaluated.
calibrated, and methods of identifying and resolving Provided the above tests and comparisons are found
nonconformities. Sample forms shall be included. If acceptable, the ASME designee will submit a report
testing procedure specifications or other similar docu- to the Society recommending the laboratory be accepted
ments are referenced, the Quality Control Manual shall for the purpose of conducting capacity certification
tests. If a favorable recommendation cannot be given,
describe the methods of their approval and control.
the ASME designee will provide, in writing to the
Society, the reasons for such a decision.

A-315 Testing Procedures A-316 Authorized Observers

(a) Flow tests shall be conducted at the applicant’s An ASME designee shall review and evaluate the
facility, including the testing of one or more valves experience and qualifications of persons who wish to
and other flow devices (nozzle orifice or other object be designated as Authorized Observers. Following such
with a fixed flow path) in accordance with the methods review and evaluation the ASME designee shall make
specified by this Section and ASME PTC 25-1994. a report to the Society. If a favorable recommendation
The capacity of the devices to be tested shall fall is not made, full details shall be provided in the report.
within the testing capability of the laboratory being Persons designated as Authorized Observers by the
evaluated and the National Board Testing Laboratory. ASME Boiler and Pressure Vessel Committee shall
The ASME designee will observe the procedures and supervise capacity certification tests only at testing
methods of tests, and the recording of results. facilities specified by the Committee.

212